Manufacture of resins



s PATENT oFFlcE MANUFACTURE OF RESINS Adolf Heck, Kansas City, Mo., assignor to Cook Paint & Varnish Company, Kansas City, Mo., a corporation of Delaware UNITED STATE No Drawing. Application March so, 1931,

Serial No. 526,568

11 Claims. (Cl- 260-4) This invention relates to the manufacture of phthalic anhydrid with phenols under the influresins; and it comprises an improvement in the enee of aluminum chlorid. vFerric chlorid and art of producing heat hardening resins from phezinc chldrid may also be used but are not better. nols, wherein a phenol is initially condensed with The product of the reaction is an indefinite ma- 5 phthalic anhydrid in the presence of certain terial; its con P y a ying in de- 5 catalysts and the phenol-phthalic anhydrid contail with the details of operation. For my purdensation products are reacted with an aldehyde poses however the exact chemical nature of the and the aldehyde reaction product partially resincondensation product is not material. Phenol ifled with the aid of heat until a resinous product itself or any of its homologues such as cresols, soluble in alcohols, esters and ketones is ob- Xylenols, etc'., may be used. 'Each specific phenol tained, the resinous products being sometimes makes a specifically different product; but all esterified with glycerine or other polyhydric alcothe products are useful for the present purposes. hols, and it further comprises the products of Ordinarily I employ two phenol molecules for such process; all as more fully hereinafter set each phthallc anhydrid molecule. While I have forth and as claimed. indicated the use of anhydrids, I may use the In some of the heat hardening resins the funcorresponding organic polycarboxylic acids. damental structural unit is a cyclic carbon com- The initial condensation products in my process pound united to an aliphatic group, both the ring contain, in addition to the carbocyclic nucleus, and the chain carrying hydroxyls (.OH) On both hydroxyl and carboxyl groups. The reaction heating bodies of this structure condensation and product so far formed, whatever its nature, is not 20 polymerization take place with formation and complex enough to give a good heat hardening elimination of H20; molecules uniting to form resin. I therefore treat the reaction product in complex groups. The action is progressive and various ways to form more complex bodies resinithe longer it continues the less is the fusibility and fiable to valuable resins, usually after rough purithe solubility of the heated material in the ordification to get rid of the catalyst. These second- 25 nary solvents. In making, phenol-formaldehyde ary treatments are of the two general types indicondensation products the primary action of the cated ante or are modifications of these general formaldehyde is theproduction of phenol alcohols classes.

or bodies containing a phenolic .OH and a methyl A particular embodiment of the present invenalcohol residue 811 0 group CH2OH. tioninpreparing an initial condensation product 30 Afterwards, these condense with each other as of a phenol with phthalic anhydrid is as folstated. It is usual to employ cresols in lieu of lows:

phenol itself; one reason being that the primary Examp 1 structural unit, or phenol alcohol, is somewhat more complex. In making resins by partially es- Approximately two molecules of ordinary phe- 35 terifying phthalic anhydrid with glycerin and nol are reacted with approximately 1 molecule of subsequently heating, the phthallc anhydrid furphthalic anhydrid in the presence of freshly subnlshes the ring group and the glycerin the alilimed aluminum chlorid as a Ca y In P at r ping, 190 parts of phenol are heated to a temper- 40 I have found that in b h W ys o ak ng eS- ature of to C. and then 148 parts of phthalic 4o ins, improved results areobtained by preliminaranhydrid mixed with the heated phenol. After y C ng the p o with phthallc anhydrid. a homogeneous solution is obtained, 10 to 50 parts In 50 doing 001111118X bQdieS are b a ed wh ch of aluminum chlorid are slowly added. A violent Contain phthalic residues combined with Phenol reaction occurs and the temperature rises to about 45 residues in Various Ways and these budies when to C. After completion of thisinitial 45 r a d with formaldehyde esterified with glycviolent reaction, the reaction mixture is held at e v Still more complex. Structural units for 120 until a gelatinous mass is obtained; approxcondensation an polymerization, passing ov imately two hours being required for the formainto resins more smoothly and giving better resti of the gelatinous mass.

50 ins. Not so much heating is required to produce The product thus obtained is an initial con- 50 a. given degree of infusibility a insolllbility from densation product which by subsequent secondary initially fusible and soluble resinified products. treatments can be converted into valuable resins. The solubilities and fusibilities of the initial prod- The product may be used in its crude state or uets are better. it may be more or less purified and refined in 55 In the present invention I first condense any suitable manner. The crude reaction prodnot is quite acid in nature and contains residues of the catalyst. When it is desired to have a secondary condensation eifected by means of an acid catalyst, the crude product may be directly wed. If it is desired to have the secondary reaction occur in the presence of an alkaline catalyst, the acidity of the raw reaction product may be removed by washingor by other purification or it may be merely neutralized with any suitable base. The reaction product is of rather indefinite constitution, but it probably contains para-dioxytriphenylcarbinol-o-carboxylic acid, or the lacetone of that compound which is phenolphthaleln where ordinary phenol (CaH5.0H) is the phenol used; or both the acid and the lactone. However, the exact nature of the complex reaction products is not here material, it being suiilcient that they are useful for the present purposes; that they may by suitable treatment hereinafter set forth be converted into certain new and valuable resins.

In the above example phenol (carbolic acid) may be replaced by similar phenolic bodies such as cresols or xylenols. Also the phthalic anhydrid may be replaced with phthalic acid or by another suitable polybasic acid of the cyclic series. The material produced with the aid of aluminum chlorid from a phenol and phthalic anhydrid contains carboxyl groups and phenolic hy- It may be treated in several ways within the purview of this invention to make useful resins. In one such way of treatment the residual carboxyl groups are simply esterified with glycerln, glycol or the like. This gives a complex molecule and good resins.

either or both ways, on heating give resinous bodies of decreasing solubility and progressively higher melting point; the decrease and the increase being something like those occurring with other heat hardening resins.

In another method of operation producing valuable resins, the initial condensation product is further condensed with formaldehyde, being thereby carbinolated. By carbinolated" I mean the introduction into the phenol-phthalic anhydrid condensation product of a CH=OH group, herein termed a carbinol grou This condensation or reaction with formaldehyde is illustrative of the addition of a simple aliphatic chain containing a hydroxyl group, to the aromatic nuclei of the initial condensation product.

Example 2 100 parts of an initial reaction product obtainable as set'forth in Example 1, are reacted at a temperature of about 130 C. with 5 to 25 parts of commercial solid formaldehyde (paraform) or with 25 to 75 parts of aqueous formaldehyde of the usual 30-435 commercial aqueous solution. A violent reaction takes place, and after it has subsided, the reaction mixture may be further heated at about 170 C., to insure complete reaction. There are obtained light elastic resins as primary reaction products- These are completely soluble in alcohols, esters and ketones; Many are also soluble in hydrocarbons such as benzol and oil of turpentine. In cases where the resins so produced are not completely soluble in hydrocarbon solvents, an addition of a small amount of alcohol gives a homogeneous solution.

They are useful in making spirit varnishes,

yellow, clear enamels and lacquers.v Further when heated to the proper temperatures, they are fusible and may be heat-hardened; and may therefore be advantageously used in making molding compositions from which molded articles may be pro- 5 duced by means of heat and pressure. They are somewhat acid in character and this is advantageous in certain molding compositions. Further resiniflcation tends to reduce their acid character. However, for some uses, it is desired that the resin be less acid or be substantially neutral. In such cases, the initial resins may be esterified with a polyhydric alcohol, such as glycerin, to reduce their acidity. For instance, about 5 per cent of glycerin may be added to the reaction mixture just prior to the final heating at 170 C. or the acid resin may be subsequently esteriiled with glycerin by heating an admixture to the required temperature; the degree of esteriflcation being so controlled to give the desired acidity or a neutral condition as may be desired. Some of the esterifled resins produced under the present invention have an acid number of about 30. These modified esters are pale-colored resins; the solubilities being about the same as those of the initial resins. They are useful in making spirit varnishes, enamels and lacquers. They are also fusible and heat-hardening, and may be used in making molded articles under the influence of heat and pressure. The heat hardened derivatives are hard, infusible and insoluble bodies.

Another way of making condensation products also uses formaldehyde in the presence of a catalyst. A typical example-is:

Example 3 100 parts of a reaction product formed by the process of Example 1, using cresol in place of phenol, are heated to a temperature of about 100 C. 5 to 20 parts of hexamethylenetetramin methylenetetramin catalyzes the reaction of the formaldehyde. In place of the hexamethylenetetramin there may be used 80 to 340 parts 01345 formaldehyde and 1 to 5 parts of ammonia in aqueous solution. In either event a vigorous reaction occurs and there is formed a light, yellow elastic resin. It is soluble in alcohols, esters and ketones; and is almost completely soluble in hydrocarbons, such as benzol. A slight addition of alcohol to solutions in benzol and like hydrocarbons asists in forming a clear homogeneous solution. Resins of this type may be used in making spirit varnishes, enamels and lacquers. Further, when heated to proper temperatures they are fusible and may be heat-hardened. They may I be formed into molded articles by means of heat and pressure. They have an acid number between 30 and 40. While they are not so acid in character as the initial resins produced in Example 2, they may be sufllclently acid to be esteriiled with polyhydric alcohols, such as glycerin, in a manner similar to that given in Example 2. Such esterifled products are pale-colored, neutral, hard resins. They are soluble in alcohols, ketones and esters and in most cases in hydrocarbon solvents, such as benzol and the like. with benzol and like solvents, a small amount of alcohol facilitates obtaining clear solutions. They may be used in making spirit varnishes, enamels and lacquers.

The ester-med products are also fusible and capable of heat-hardening. They, like the unresins from which they are derived, are

. compositions in advantageous materials to use in compounding molding compositions from which articles may be made by'hot molding which are insoluble, infusible bodies. In making molding compositions from either the esterified or unesterifiedresins, I find that it is sometimes advantageous to add a small amount of hexamethylenetetramin to the resin. Such addition facilitates the conversion of the resins into insoluble and infusible bodies in hot molding.

In disclosing certain applications of my new resins, I refer to spirit varnishes, oil varnishes, enamels and lacquers. I use such terms in a broad and generic sense. By spirit varnishes I mean generally solutions of the resins in volatile solvents irrespective whether this solvent is ethyl alcohol or a like solvent; the final varnish film being formed mainly by evaporation of a solvent. An oil varnish is,a varnish which gives a film by drying, polymerization or other complex reaction, rather than by a direct evaporation of a solvent. These oil varnishes may be made by melting or blending the resins with a drying oil or similar vehicl'. Of course, blending agents and -501- vents which are volat' e may be used; but the formation of the film is primarily due to other causes thanthe evaporation of the co-solvent or blending agent. I likewise use the term enamel in a broad sense, meaning either a spirit or oil varnish which has been pigmented, that is, such varnishes containing pigments, extenders and the like. In the scope of the term lacquer I include which a resin is blended with cellulose derivatives; the blended, film-forming ingredients being dissolved or dispersed in the vehicle. These lacquers may also include the socalled plasticizers such as dibutyl phthalate, tricresyl phosphate, diethyl phthalate, and like materials. With these lacquers the film is primarily formed by evaporation of the solvent or vehicle. My new resins are different from the materials heretofore used in making such varnishes, enamels and lacquers and the properties of these new resins are somewhat different in certain respectsfrom the materials heretofore used. While the primary formation of the film may be similar to that with the prior art, the new resins give a somewhat superior coating or film. The new resins due to their quite different properties may undergo some reaction or condensation or polymerization which modifies the formation of the film and accounts for the superior excellence of these coatings. Many of my resins are capable of being heat-hardened to give infusible, insoluble resinous bodies and are useful as binders. The coatings produced with the varnishes, enamels and lacquers derived from my new resins may be heat-hardened to further improve the film coat.

The above examples illustrate typical embodiments of my generic process. The amounts of materials used, the materials themselves, the temperatures and other conditions under which both the initial and secondary condensations are effected may be varied within wide limits to produce specific resins having the desired characteristics for a particular application. In making the initial condensation phenol may be replaced with cresols, xylenols and similar phenolic bodies and the phthalic anhydrid may be replaced with phthalic acid or other suitable polybasic acid of the cyclic series. The initial reaction products formed from any of these materials may be subjected to a secondary condensation. In the secondary condensation which involves adding a carbinol group, that is a hydroxylated side chain by reacting with an aldehyde, any suitable aldehyde such as formaldehyde, acetaldehyde, acrolein, furfural and polymers of such aldehydes or compounds yielding the aldehyde such as hexamethylenetetramin, may be used. In the sec- 5 ondary condensations involving the addition of a hydroxylated side chain by esterification of acid groups, glycerin, glycol or like polyhydric alcohols may be used. Free fatty acids or resin acids may also be used for esteriilcation of hydroxyl groups. Abietic acid and monkopalin" acid etc., are typical resin acids. The fatty acids of linseed oil, wood oil, perilla oil, soy bean oil, castor oil, etc. are advantageous. The fatty oils themselves may be used as they contain both a fatty acid and glycerin. When the fatty oils are used directly there seems to be an interaction or reaction between the oil and the initial condensation products of the type produced in Example 1. It is advantageous however to use the glycerin and the fatty acid as individual, reactants as better control is possible in such cases.

' The esterification of the initial reaction products is itself a distinct type of secondary condensation within the scope of my invention, but such esterification may also be used as a further modification of secondary condensation products made by reaction with formaldehyde and the like.

What I claim is:

1. As an improvement in the manufacture of useful complex resins from phenols and aldehydes, the improvement which comprises condensing about 2 mols of a phenol with 1 mol of an anhydrid of an aromatic dicarboxylic acid 85 in the presence of an inorganic catalyst of the class consisting of chlorides of aluminum, iron and zinc, reacting 100 parts of the condensation product thus obtained with between 5 and 25 parts of an aldehyde saidparts being parts by 40 weight and partially resinifying the aldehyde reaction product by heating said reaction product to about 170 C. until a resinous product soluble in alcohols, esters and ketones is obtained.

2. The process of claim 1 wherein said anhydrid is phthalic anhydrid.

3. The process of claim 1 wherein said aldehyde is formaldehyde.

4. As an improvement in the manufacture of useful complex resins from phenols and. alde hydes, the process which comprises .adding an aromatic dicarboxylic acid anhydrid to a molten phenol in 'a molecular ratio of approximately 1:2 of anhydrid to phenol, adding aluminum chloride to the homogeneous solution thus obtained,'permitting the first violent reaction to subside and then heating the reaction mixture until the reaction is substantially complete and a gelatinous mass is obtained, adding an aldehyde to the gelatinous mass thus obtained, permitting the first reaction to subside and then heating the aldehyde reaction mixture until a partially resinified complex resin soluble in alcohol, esters and ketones is obtained.

5. The process of claim 4 wherein a polyhydric an aliphatic alcohol is added to the aldehyde reaction product prior to said partial resiniilcation by heating thereby producing upon said partial resinification an esterifled resin having a reduced acid number and improved solubility.-

6. As an improvement in the manufacture of useful complex resins from phenols and aldehydes, the steps which comprise heating approximately 190 parts of phenol between and 0., adding about 148 parts of phthallc anhydrid to 75 the heated phenol, continuing the heating until tones, and being capable of conversion into ina homogeneous solution is obtained, slowly addsoluble and iniusible bodies by further heating. ing between to parts of aluminum chloride 8. The process of claim 1 wherein the reaction to the said solution, permitting the first violent with aldehyde is efl'ected in the presence oi. an reaction to subside and then heating the reacalkaline catalyst. 5 tion mixture to about C. until the reaction 9. The process of claim 1 wherein the said conis substantially complete and recovering the condensation product obtained by condensing a phedensation product thus obtained, mixing about 1101 with anhydrid of an aromatic carboxylic acid 100 parts 'of said condensation product with 5 is reacted with hexamethylene tetramine, toi'orm to 25 parts of actual formaldehyde, heating the said aldehyde reaction product, said reaction be- 10 mixture to about C. until the initial vigorous ing automatically eflected under alkaline conj reaction subsides and then continuing the heatditions.

ing at about C. until a partially resinified 10. The process of claim 1 wherein said parproduct soluble in alcohols, esters and ketones is tially resinified product soluble in said solvents obtained, said product being a light yellow clear is subsequently subjected to heat and pressure to 15 elastic resin. form shaped, insoluble, infusible articles.

7. As new and improved intermediate resins, 11. The process of claim 6 wherein said parthe light colored, elastic complex resins obtaintially resinified product soluble in said solvents able by the process of claim 1, said complex resins is subsequently subjected to heat and pressure being partially resinified aldehyde reaction prodto form shaped, insoluble, infusible articles. 20 nets of a phenol-phthalic anhydrid condensation product, being soluble in alcohols, esters and ke- ADOLF HECK. 

